Rear Window Shattered Twice – Possible Thermal Issue?

[Lightning64]

Well, we found the reason for the rear glass shattering!

When the glass installer was removing what was left of my rear window, they discovered that the wiring connector for the rear defroster was completely MELTED! It wasn’t just damaged—it was a glob of melted plastic fused with glass shards.

This pretty much confirms that the issue was overheating in the rear defroster system, which likely caused thermal stress on the glass until it failed.

 

[Grumpy2]

Wow, but what caused it to overheat, just being on too long? Reminds me of the heated back seat discussion. I still have concerns why just your truck has got too hot twice ...
Do you think that is the original connector, that was in place when the first window burst? It looks from your photos the source of the heat was the hottest at the contact point (splice) where the wires are secured to those within the window. The more contact area, the less heat at that point.

 

[GDN]

Well, we found the reason for the rear glass shattering!

When the glass installer was removing what was left of my rear window, they discovered that the wiring connector for the rear defroster was completely MELTED! It wasn’t just damaged—it was a glob of melted plastic fused with glass shards.

This pretty much confirms that the issue was overheating in the rear defroster system, which likely caused thermal stress on the glass until it failed.

So did the dealer do the replacement as warranty then?

 

[chl]

I guess I should be glad my 2023 Pro doesn't have the rear defroster.

I've had many a vehicle made by other OEMs with rear window defrosters and never saw a broken or cracked rear window.

Interesting Ford had so many issues with that problem over the years.

Either the glass manufacture and/or install/design, or the heating elements/controller that Ford has been using through multiple years has to be to blame.

Seems like they could have figured that out and remedied the problem years ago.

Probably a cost benefit calculation decided that a few broken rear windows would cost Ford less than changing the design elements, eh?

Such is business sometimes...

 

[Henry Ford]

Probably a cost benefit calculation decided that a few broken rear windows would cost Ford less than changing the design elements, eh?

This is my guess. A certain amount of failure is the cost of doing business. A truck isn't an airplane.

 

[The Weatherman]

Well, we found the reason for the rear glass shattering!

When the glass installer was removing what was left of my rear window, they discovered that the wiring connector for the rear defroster was completely MELTED! It wasn’t just damaged—it was a glob of melted plastic fused with glass shards.

This pretty much confirms that the issue was overheating in the rear defroster system, which likely caused thermal stress on the glass until it failed.

Well that can’t be good.

 

[chl]

Wow, but what caused it to overheat, just being on too long? Reminds me of the heated back seat discussion. I still have concerns why just your truck has got too hot twice ...
Do you think that is the original connector, that was in place when the first window burst? It looks from your photos the source of the heat was the hottest at the contact point (splice) where the wires are secured to those within the window. The more contact area, the less heat at that point.

Bad solder joints can lead to hot spots like that, or any loose or corroded connection, like when people don't torque down their FCSP power wires or in a breaker box.

Made in China? I have seen a lot of bad solder joints in inexpensive stuff made in China - light fixures, solar cells on outdoor lights etc. Sometimes I can resolder them, other times it's back to the store for a refund.

Had a GE hybrid water heater that had bad welds on the compressor tubing - GE tech came out and looked it over, then they replaced the whole water heater...then that one failed the same way, and Sears came out and replaced that one...then that one failed! So Sears came out and looked at it, ordered a part - from China, which took several months - then welded the part on.

I bought it with the 5 year service contract free when it was on sale. The water heater paid for itself in less than a year in lower electric bills, but what a hassle with repairs!

That glob of plastic on the wiring might have been a seal on the solder joints between the car wiring and the heating element in the glass.

My theory anyway.

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